Load-Sensing Hydraulic Pressure Regulation for Variable Standby Flow
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Solution Overview
Problem
Existing hydraulic systems with Load Sensing technology face inefficiencies in pump operation, particularly when lower flow rates are required, and high standby consumption and dissipation, limiting flexibility and optimization.
Innovation Solution
A hydraulic system incorporating a 2-position 3-way proportional valve controlled by proportional pressure reducing valves, allowing for management of the pressure jump between supply and Load Sensing pressures, enabling adjustable flow rates and reduced standby consumption based on operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed standby pressure is imposed via dosing niches of the slider, then a fixed flow rate is imposed independent of the LS pressure, but the pump standby consumption and dissipation increase
Solution Approach 1:
The patent applies dynamics by making the standby pressure variable rather than fixed. The dosing niches of the slider are configured to impose a standby pressure that varies according to the Load Sensing (LS) pressure level. When LS pressure is high, the standby pressure is reduced, and when LS pressure is low, the standby pressure is increased, allowing the pump to operate more efficiently across different operating conditions while maintaining proper flow control.
Solution Approach 2:
The invention changes the parameter of standby pressure from a fixed value to a variable value that depends on the LS pressure. By configuring the dosing niches to create a pressure relationship where standby pressure = f(LS pressure), the system adapts its pressure parameters dynamically, reducing energy loss while maintaining flow control independence from LS pressure variations.
2Loss of energy
If the pump sends only the flow rate necessary to generate the pressure jump imposed by the flow rate regulator, then energy consumption is reduced, but the system loses flexibility in managing pressure jumps under different operating conditions
Solution Approach 1:
The system dynamically adjusts the pressure jump management based on operating conditions. The dosing niches of the slider automatically modulate the standby pressure according to the LS pressure level, allowing the pump to maintain optimal energy consumption while the system adapts to different operating conditions. This dynamic adjustment provides flexibility without requiring active pump control modifications.
Solution Approach 2:
The dosing niches of the slider perform a self-service function by automatically regulating the standby pressure based on the LS pressure. The system uses its own operational parameters (LS pressure) to automatically adjust the pressure jump management, eliminating the need for external control mechanisms while maintaining both energy efficiency and operational flexibility.
3Device complexity
If traditional Load Sensing systems use a fixed compensator, then the system structure is simple, but the system lacks adjustment variables to optimize different conditions of use
Solution Approach 1:
The invention introduces local quality by configuring the dosing niches of the slider with specific geometric characteristics that create a variable standby pressure effect. Instead of using a uniform fixed compensator, the dosing niches are designed with local variations in their structure (dimensions, positions, orientations) that enable them to impose different standby pressure levels depending on the LS pressure, thereby adding regulation flexibility to the otherwise simple Load Sensing structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances regulation flexibility, optimizes energy consumption, and allows for variable torque control, improving system efficiency and sensitivity by managing pressure jumps and standby values dynamically.
Implementation Method 1
two proportional pressure reducing valves (5, 6) arranged to provide a reduced pressure signal (pr1, pr2) to the proportional valve (4)
Implementation Method 2
a 2-position 3-way proportional valve (4) supplied by the supply channel (2) and connected to the flow rate regulator (11) of the pump (12) via a supply channel (31) for a conditioned pressure signal (LSc)
Implementation Method 3
a channel (30) configured so as to receive from the sections of the valve distributor a Load Sensing signal, to which a respective Load Sensing LS pressure corresponds
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
A hydraulic system comprises a valve distributor comprising one or more sections connectable to respective uses, a supply apparatus comprising a pump and a supply channel, a discharge channel connected to a low-pressure tank, a use signal channel coming from the section of the valve distributor and further comprises a hydraulic regulating device connected via said channels which includes a 2-position 3-way proportional valve configured so as to provide operative fluid at a conditioned pressure, different with respect to the pressure that is characteristic of the operative condition of use, to the supply apparatus and at least one proportional pressure reducing valve.